Container for packaging yarn cones



March 21, 1961 J. P. H. LEAVlTT CONTAINER FOR PACKAGING YARN CONES 5Sheets-Sheet 1 Filed June 16, 1958 frzz/enfof Jzmesfffleaz/ iii %%%w@March 21, 1961 J. P. H. LEAVlTT CONTAINER FOR PACKAGING YARN CONES 3Sheets-Sheet. 2

Filed June 16, 1958 fnvenibr K162771495 PHLeczz/L'ZZ March 21, 1961 J.P. H. LEAVlTT 2,975,892

CONTAINER FOR PACKAGING YARN CONES Filed June 16, 1958 3 Sheets-Sheet 5CONTAINER FGR PACKAGING YARN CONES James P. H. Leavitt, Wayne, Pa,assignor to Container Corporation of America, Chicago, ill., acorporation of Delaware Filed June 16, 1958, Ser. No. 742,284

4 Claims. (Cl. 206-65) This invention relates generally to shippingcontainers, and more particularly to improved partition or trayconstruction therein for positioning and retaining cones of yarn, orlike material.

It is the general object of the present invention to provide a shippingcontainer having inner tray construction designed to retain and supportcones of material in separate and fixed positions, whereby said materialis held free from contact with the tray, walls of the container, andother cones of material.

An important object of this invention is to provide in a shippingcontainer having inner tray construction as described, trays orpartitions arranged alternately with cones of material whereby trays ofcones are disposed in a stacked or layer positionment and wherein eachtray is formed to permit disposition of the top terminal portions of alayer of cones within the base portions of an adjacent layer of cones.

Another object of this invention is to provide in a shipping containerhaving alternately stacked trays and cones of material therein asdescribed, a tray or partition designed to position and support adjacentlayers of cones on either side or" said tray.

A further object of this invention is to provide in a shipping containerhaving inner tray construction designed to retain and support cones ofmaterial in separate and fixed positions, a tray formed to accommodateon the upper side thereof the base of a cone, and on the under side thetop terminal portion of an underlying cone.

A still further object of this invention is to provide a tray of thecharacter stated which is formed of two blanks cut and scored in acomplementary manner to afford interlocking portions which are adaptedto retain and support cones of material.

To achieve the foregoing objects it is contemplated that a shippingcontainer be provided with multiple inner trays, each of whichaccommodates a plurality of cones of yarn, said trays being arranged instacked or layer positionment whereby each immediate overlying tray issupported by the cones of yarn positioned on the underlying tray. Eachtray is formed from a base sheet and a top sheet interlocked in acomplementary manner to provide a pluralityof upwardly extendingprojections, each projection being adapted for disposition of the baseportion of an overlying cone thereupon and the insertion of the upperportion of an underlying cone therein. The interlocking arrangement ofsaid base and top sheets is such as to permit shipment of the sheets inflat condition, and upon assembly afford positive engagementtherebetween to provide a uritary tray member. The projections of eachtray resulting from and comprising interlocking elements of the sheetsare designed to present suitable surfaces for engaging and positioningcones of yarn on both sides of the tray. Aiter the shipping container isproperly packed with layers of cone bearing trays, inner cover means areprovided which cooperate with the top tray to engage and position thetop layer of cones, where- 2,975,892 Patented Mar. 21, lQfil by topermit closure and securernent of the container cover flaps for completeshipping container assembly.

Further objects, features and advantages of the invention will appear orbe apparent to one skilled in the art from the following description,reference being made to the accompanying drawings, in which:

Fig. 1 is a plan view of the blank from which the base sheet of the trayis formed.

Fig. 2 is a plan view of the blank or top sheet of the tray and which isdesigned to overlie the base sheet.

Fig. 3 is a fragmentary plan view on an enlarged scale of a portion ofthe blank of Fig. 1 showing rectangular members in abutting position andthe connecting strips therebetween buckled upwardly.

Fig. 4 is a fragmentary plan view on an enlarged scale of a portion ofthe blank of Fig. 2 showing the cut out portion which is adapted toreceive and interlock with the buckled connecting strip.

Fig. 5 is a plan view of the projection formed through assembly of thecomplementary base and top sheet portions of Figs. 3 and 4,respectively.

Fig. 6 is an elevational view, with portions broken away of a pluralityof cones of material in stacked relation with trays.

Fig. 7 is an enlarged vertical sectional view of a tray projection, withthe underlying cone shown in dot dash line, taken on line 77 of Fig. 6.

Fig. 8 is a vertical sectional view taken on line 8-8 of Fig. 7.

Fig. 9 is a horizontal sectional view taken substantially on line 9-9 ofFig. 7.

Fig. 10 is a fragmentary plan view on an enlarged scale of a top sheet,showing a modified cut out portion adapted to receive and interlock withthe buckled connection strip.

Fig. 11 is a plan view of the projection formed through assembly of thecomplementary base and top sheet portions of Figs. 3 and 10,respectively.

Fig. 12 is a vertical sectional view of the tray projection of Fig. 11,shown in operative position with overlying and underlying cone portions.

Fig. 13 is a plan view of the base sheet of an inner cover lockingassembly.

Fig. 14 is a plan view of the top sheet of the inner cover lockingassembly.

Fig. 15 is a sectional view of the top portion of an assembled shippingcontainer showing the inner cover locking assembly.

Fig. 16 is a vertical sectional view of a shipp ng container havinginner tray construction according to the teaching of this invention.

Referring now to the drawings, and particularly Fig. l, the referencenumeral 10 indicates a one-piece paperboard blank of rectangular shapefrom which the base sheet of the tray is formed. The blank is cut andscored. to provide spaced apart rectangular members 11, 12, 14.,v and15, connected by a plurality of strips 16, each strip being hingedlyconnected to adjacent rectangular members along scorelines l8 and havinga centrally located transverse cut-score 19. Each connecting strip isformed to present similarly shaped portions on either side of thecut-score 19, comprising side edges 22 converging away from thescorelines 18 and side edges 23 converging away from the cut-score 19,said edges 22 and 23 having an arcuate edge portion 24 therebetween. Thespaced apart rectangular members are displaced or pushed together toplace the edges of adjacent members in a position of abutment, therebybuckling the connecting strips 16 upwardly to form inverted V-shapedprojections 26, see Fig. 3. Also, as shown, upon displacement of theconnecting strip upwardly and abutment of the adjacent rectangularmembers, arcuate edges 24a of said membets are exposed, said edges ofadjacent rectangular members being aligned and cooperating to presentcomposite arcuate edge 27.

Referring now to Fig. 2, the reference numeral 30 indicates a one-piecepaperboard blank or top sheet, adapted to overlie the base sheetin'assembly, having a plurality of cut out portions 31 formed therein.Each cut out portion or pocket Sihas oppositely disposed arcuate edges32 and, arranged at right angles thereto oppositely disposed angulateedges 34. For a purpose to be explained, each arcuate edge 32 isbisected by a slit 35.

As seen in Figs. 1 and 2, top sheet 30 has a plurality of pockets 31,which in number and relative disposition are designed to coincide withthe number and disposition of projection 26, formed when the base sheetit is manipulated to displace connecting strips 16 upwardly. Placing thetop sheet upon the erected base sheet will cause projections 26 toextend upwardly through pockets 31, superposing the arcuate edge 32 ofthe top sheet upon the arcuate edge 27 of the base sheet, see Fig. 5. Itis noted that the Width of the projection 26 at cut-score 19 is greaterthan the pocket opening 31 defined by opposing arcuate edges 32, and inthis respect slits 35 permit distortion upwardly of the pocketperipheral portions 36 upon insertion of the projection into the pocket.In eifect, portions 36 are cammed upwardly and outwardly by projectionedges 23 and 24, whereupon when the projection 26 is fully seated, i.e.,when top sheet 30 rests upon base sheet 10, said portions 36 are free toand do return to their original planar disposition, as illustrated. Thepocket peripheral portions 36 extending under the inverted V-shapedprojection act as locking tabs preventing the collapse or withdrawal ofsaid projection from the pocket.

In the assembly of the shipping container for packaging cones of yarn40, see Fig; 16, the tray construction for separating, supporting, andpositioning layers or tiers of cones, is utilized in the followingmanner. With base sheet it) in erected position and top sheet 30disposed thereon and interlocked therewith, each projection 26 is suitedto accommodate two yarn cones, one overlying the projection, and oneunderlying the projection. Such accommodation and disposition of trayand yarn cones is illustrated clearly in Figs. 6, 7, and 8.

As shown, a yarn cone base 41 is disposed over projection 26, with theterminal portions 19a of the pro jection apex at out score 19 being infrictional engagement with the cone inner surface, thereby maintainingthe cone in position against lateral movement. An underlying yarn coneapex 42 is disposed in cut-out portion or pocket 31 and is engaged bythe arcuate edges 32 and 27 of the top sheet'3ti and base sheet 10,respectively, the taper of the cone limiting insertion of the'cone apexinto and through the cut-out portion. It is preferred that the normaltaper of the cone be interrupted at the cone apex to provide a'cylindrical portion, as shown,

whereby to afford a snug fit with the arcuate edges 32 and 27, althoughit is obvious that even if the normal taper of the cone continues to thecone apex the cut-out portion would accommodate said apex.

Fig. 9, which is a horizontal sectional view taken through the base of ayarn cone, shows the relative disposition of the cone base 41, whichencircles projection 26, and cone apex 42, which is disposed within theprojection.

Referring now to Fig. 10, there is shown a fragmentary plan view of atop sheet having a modified cut out portion or pocket 31. The modifiedpocket 31 while having a similar shape and function as that describedfor pocket 31, is distinguished therefrom by the edges 32 which arearcuate in a manner and direction opposite to the arcuate'edges 32of'p'ockets '31, i.e., edges 32 extend inwardly to reduce the pocketopening and do not define an arcu'ate surface for accommodation of thecone apex. Slits 35', which function as do slits 3510 permit insertionof a projection into the pocket, cooperate with scorelines 45 to definedisplaceable peripheral portions 36'. Upon insertion of the projection26 into pocket 31', the portions 36' are cammed upwardly and outwardlyby projection edges 23 and 24, and upon full insertions of theprojection said portions return to their original planar dispositionunderlying the projection, see Fig. 11.

As seen in Fig. 12, disposition of the base 41 of a yarn cone upon aprojection will result in terminal portions 19a of the projection apexat cut-sc-ore'19 frictionally engaging the cone inner surface. Insertionof a yarn cone apex 42 from under the projection into the pocket 31'will result in the cone apex displacing portions or tabs 36' upwardlyabout their scorelines 45. Such displacement of the portions 36upwardly, wedges said portions against the projection undersurface,thereby presenting a firm abutment or stop arrangement for the coneapex. This modified construction is most useful when the cone apex is acontinuation of the cone taper and is adaptable to con% of varioussizes.-

Having described the tray construction which provides for layer stackingof yarn cones, reference is now made to Fig. 16 wherein the layers ofyarn cones are shown enclosed in a container 50. The container, asshown, is of well known construction, having a four sided tubular body51, wherein each side panel has end fiaps which cooperate to form endclosures 52.

When packing the yarn cones in the container, whether from a sideopening panel or the top, the alternate stacking of trays and yarn conesresults in the final or top layer of cones being unsupported by anoverlying tray construction. To provide support for the top layer ofcones an inner cap construction 55 is utilized, comprising a pad 56 anda wrapper or locking sheet 57. Referring to Figs. 13 and 14, there isshown plan views of the blanks from which the pad and wrapper,respectively, are formed.

Pad 56 is simply a rectangular sheet of paperboard conforming in outsidedimensions to that of the underlying tray constructions. A plurality ofholes 59 are formed-therethrough, spaced and disposed to coincide withcone disposition, whereby to rest upon the top layer of cones with theapex of each cone being disposed within a hole.

Wrapper 57 has a rectangular main panel 60 having a plurality of holes61 formed therethrough, whereby, in assembly, panel 60 will rest'uponpad 56, being coextensive therewith, and holes 61 will be aligned withholes 59. It is contemplated that whereas the cone apex will be disposedin both aligned holes, the combined thickness of material of the pad'and wrapper will prevent said cone apex from extending up and beyond thewrapper top or outer surface. The main panel 60 has oppositely disposedside flaps 64 hingedly connected thereto, and oppositely disposed sideflaps 66 hingedly connected thereto, the latter flaps each terminatingat their free edge in a tab 68 articulate therewith. When main panel 60is positioned upon pad 56, side flaps 64 and 66 are folded downwardly tolay adjacent the inner surface of the container side walls. As see inFig. 15, flaps 68 extend downwardly to and adjacent a tray construction,tab 68 being tucked inwardly to disposition between the base sheet 10and top sheet 30. It is intended that such inner cap construction willretain the top layer of cones as a unit, and will prevent individualmovement of said top cones when initial packing compression has beendissipated, due to settling and crushing of the packed contents afterlong storage, either in inventory or in transit.

From the foregoing description it is apparent that trays constructedaccording to this invention will retain and support layers of 'yarncones in separate and fixed position, each cone being suitably securedat its base and at its apex. Each tray is'formed to accommodate the apexof an underlying'cone and the base of an overlying cone, suchaccommodation being provided by an inverted V-shaped projectionextending upwardly to disposition within the base of an overlying coneand Wl'llCh receives the apex of an underlying cone therein, each traybeing constructed of superposed sheets of paperboard interlocked by andat said projection. This interlocking of the superposed sheets at theprojection while easily accomplished provides a positive locking actionpreventing separation of said sheets, said projection maintaining theadjacent cones'from movement.

While the foregoing specification sets forth the invention in specificterms, it is understood that many variations and modifications may beresorted to without departing from the broad aspects of the invention asdefined in the appended claims. Having now described the invention, whatis claimed rs:

l. A yarn cone package comprising a plurality of superposed layers ofspaced yarn cones, each of such cones being of hollow, fmsto-conicalform, a plurality of trays interposed between adjacent layers of cones,each tray comprising a base sheet and a top sheet of paperboard, thebase sheet being cut and scored to provide a plurality of upwardlyextended, inverted, V-shaped projections, the lower ends of the legs ofwhich are hingedly connected to the base sheet along parallel foldlines, such projections being cut from within the contour of the basesheet, whereby apertures are formed when the projections are foldedupwardly, marginal edge portions of concave, arcuate shape formed in thebase sheet at such apertures and disposed in circular relationsymmetrically below the apex of each of the V-shaped projections. thetop sheet being disposed in flatwise relation upon the base sheet, saidtop sheet being cut to provide a plurality of pocket-forming aperturesin registration with the projections and through which the projectionsare disposed, the marginal portions of the top sheet around theapertures therein including portions extending below the legs of theinverted V-shaped projections and in interlocking contact with the lowerend portions of such legs near their hinged connection with the basesheet, the lower ends of cones above the tray being arrangedtelescopically over the projections, and the upper ends of cones belowthe tray being received into the circular apertures formed by saidarcuate, marginal edge portions in the base sheet disposed below theprojections.

2. A yarn cone packaged as defined in claim 1, in

which the inverted V-shaped projections are of such parallel fold lines,such projections being cut from within the contour of the base sheet, sothat apertures are formed when the projections are folded upwardly;marginal edge portions of concave, arcuate shape formed in the basesheet at said apertures and disposed in circular relation symmetricallybelow the apex of each of the V-shaped projections; said top sheet beingdisposed in parallel abutting relation upon the base sheet and being cutto provide a plurality of pocket-forming apertures through which saidprojections are disposed; and marginal portions formed in the top sheetat said last mentioned apertures including portions extending inwardlybeneath the legs of the inverted V-shape projections and in interlockingcontact with lower portions of said legs near their hinged connectionswith the base sheet operable to engage said leg portions and therebymaintain the base and top sheets in abutting relation.

4. A tray construction for cooperation with superposed, aligned yarncones packed within a shipping container, such yarn cones being ofhollow, frusto-conical form, the tray comprising a base sheet and a topsheet of paperboard, the base sheet being cut and scored to provide aplurality of spaced, upwardly extending, dihedral angle portionsconstituting invented V-shaped projections formed in substantiallyidentical half-sections, the ends of the lower portions of the legs ofthe projections being hingedly connected to the base sheet alongparallel fold lines and the upper ends of the legs being foldably joinedat the apex, the lateral edges of the lower portions of the legs beingcut symmetrically at an inclination toward each other at a small anglerelatively to a line normal to the fold line connection with the basesheet, thus providing downwardly and outwardly flaring lower endportions, the top sheet being in overlying relation to the base sheetand being formed with a plurality of spaced, pocket-forming apertures inregistration with the spaced, V-shaped projections and through which theprojections are disposed, each aperture being defined by a central,circular portion, for receiving from below the reduced upper end portionof a yarn cone, and by opposed, communicating, open portions which aresymmetrical and which have contours similar to, but smaller than, thelower portions of the legs of the V-shaped projections, the narrowerpart of each leg portion being sufiiciently small to be receeived intothe wider parts of said individual opposed open portions of the topsheet, whereby forcing the lower parts of said leg portions upwardlythrough said open portions results in a binding engagement of the legswithin such individual opposed openings, tending to hold the base andtop sheets inclose, flatwise relation.

References Cited in the file of this patent UNITED STATES PATENTS2,110,480 Barlow Mar. 8, 1938 2,631,724 Wright Mar. 17, 1953 2,818,974Talbot Jan. 7, 1958

